What are the reasons for changes in results from the lab to mass production? Causes and countermeasures for the deterioration of distributed quality during scale-up.

From powder supply to dispersion, defoaming, and transfer. A dispersion machine line compatible with high-viscosity slurries has been established.

We offer a solid-liquid mixing line that includes powder supply, dispersion, degassing, and transfer, centered around the disperser. In high solid content and high viscosity slurries, the powder supply conditions and instantaneous concentration fluctuations significantly affect dispersion quality. This system optimizes the entire process rather than just the disperser alone, achieving quality stabilization and productivity improvement. Additionally, by combining inline dispersers, batch dispersers, static mixers, etc., we can propose systems tailored to material characteristics and processing conditions. We accommodate a variety of slurry applications, including battery materials, CNTs, electronic materials, adhesives, inks, and food. We can provide consistent support from lab testing to scale-up and mass production line construction.

• Emulsifier/Disperser
• Powder Supply Device
• Dispersion/emulsification equipment/homogenizer

Resolve issues of not dissolving and clumping in advance. Test the dispersibility of the protein.

The quality of protein products is greatly influenced by their dispersion state. In particular, powdered protein often faces challenges such as clumping during dissolution in water or solvents, uneven dispersion, and poor mouthfeel. Additionally, changes in formulation or raw materials can alter viscosity and dispersibility, leading to cases where there are no issues during prototyping but quality becomes unstable during mass production. This service conducts dispersion tests tailored to raw material characteristics and formulation conditions, verifying the suppression of clumping, improvement of dispersibility, and enhancement of mouthfeel. Furthermore, through process design aimed at scaling up from the lab to small machines and mass production equipment, we establish reproducible manufacturing conditions. We can support evaluations from the prototyping stage to pre-mass production verification.

• Emulsifier/Disperser
• Dispersion/emulsification equipment/homogenizer
• Vacuum degassing machine

The strength is determined by the variance. Visualize quality variations through testing before mass production.

The performance of adhesives greatly depends on the dispersion state of fillers and additives, and even slight differences in dispersion can affect adhesion strength, durability, and appearance quality. Particularly in highly filled systems, issues such as clumping, undispersed particles, and poor mixing due to viscosity increases are likely to occur, leading to variations in dispersion and quality due to sedimentation and separation. These challenges often stem not from the equipment alone but from input conditions, dispersion conditions, and process composition, manifesting as problems that cannot be reproduced during mass production. In this service, we conduct dispersion tests based on the customer's materials and formulation conditions to evaluate the dispersion state, viscosity characteristics, and their impact on adhesive performance. Furthermore, we perform scale-up verification using small machines and pilot equipment to clarify the reproducible conditions for mass production. By conducting thorough verification that delves into process design, we support quality stability and reduction of development time.

• Emulsifier/Disperser
• Dispersion/emulsification equipment/homogenizer
• Vacuum degassing machine

Quality changes with dispersion. Pre-validation of the reproducibility of resin materials through testing.

In the dispersion process of resin materials, the dispersion state of fillers and additives greatly influences product performance. Issues such as strength reduction due to poor dispersion, appearance defects, variability in functional characteristics, and viscosity fluctuations are likely to occur, especially in high-fill and nano-filler systems where dispersion difficulty increases. Additionally, even if there are no problems during the prototype stage, it is often seen that the same quality cannot be reproduced during mass production. This service conducts dispersion tests tailored to material properties and formulation conditions, evaluating dispersion state, viscosity characteristics, and reproducibility. Furthermore, through scale-up verification using small machines and pilot equipment, risks during the transition to mass production are visualized in advance. This is not just a simple test; by delving into process design, we support quality stability and productivity improvement.

• Emulsifier/Disperser
• Dispersion/emulsification equipment/homogenizer
• Vacuum degassing machine

Verify before failing in mass production. Confirm the reproducibility of slurry dispersion in advance.

In the dispersion process of battery slurry, it is often observed that while dispersion can be achieved without issues during the research phase, it cannot be replicated during mass production, leading to quality problems. This is particularly true for positive and negative electrode slurries and CNT conductive materials, where variations in powder input conditions, dispersion energy, viscosity changes, and differences in process configuration can significantly alter the dispersion state and coating properties. Our service conducts dispersion tests at the lab scale based on the customer's materials and formulation conditions, evaluating the dispersion state, viscosity characteristics, and reproducibility. Furthermore, we support scale-up verification using small machines and pilot equipment, visualizing risks during mass production in advance. This is not just a simple test; through verification that delves into process design, we assist in reducing troubles during the transition to mass production and shortening the startup period.

• Emulsifier/Disperser
• Dispersion/emulsification equipment/homogenizer
• Vacuum degassing machine

Fukuda Co., Ltd., which develops, manufactures, and sells leak testing equipment to inspect airtightness and sealing performance, provides a technical document that clearly explains the methods and theories of airtight testing, titled "Technical Manual." We are offering it as a PDF file. Please take this opportunity to download and view it!

The pinhole inspection for packaging engineering is fully automated, eliminating packaging defects based on certain quality standards. The judgment results and operational status can be managed via a monitor screen. - Quantitative management of quality standards for the pinhole inspection process - Ensuring the quality of the product's shelf life - Establishing evaluation criteria for the manufacturing process, achieving quantitative quality assurance - Slim and space-saving design that can be connected to existing production lines - Quick changeover for product variety switching can be handled in a short time by exchanging chambers - Fully domestically produced, allowing for rapid maintenance and troubleshooting - Example target works: pillow packaging, packaged rice (packaged cooked rice), etc. *Please consult us regarding the use of this product for pharmaceuticals.

Fukuda Co., Ltd. has been pursuing leak detection for 60 years and is committed to advancing the future of leak testing. 【 Supporting Various Leak Tests: Air Leak Test / Gas Leak Test (Hydrogen Gas, Helium Gas) 】 We develop, manufacture, and sell leak testing equipment to inspect airtightness and sealing properties. We will propose the appropriate testers and devices for each inspection target. 【 Target Industries and Examples of Inspection Targets 】 - Automotive Industry: Engines, FC components, valves and piping, various parts - Electronic Components Industry: Smartphones, keyless switches, various small sensors - Pharmaceuticals / Food / Cosmetics Industry: Bottle containers, syringes, vials, eye drop containers, pillow packaging, PTP packaging We will propose the most suitable leak testers for each industry. 【 ISO Certification 】JIS Q 9001:2015 (ISO 9001:2015)

Fukuda Corporation has been pursuing leak detection for 60 years and is dedicated to advancing the future of leak testing. 【 Supporting Various Leak Tests: Air Leak Test / Gas Leak Test (Hydrogen Gas, Helium Gas) 】 We develop, manufacture, and sell leak testing equipment to inspect airtightness and sealing performance. We will propose suitable testers and devices for each inspection target. 【 Target Industries and Examples of Inspection Targets 】 - Automotive Industry: Engines, FC components, valves and piping, various parts - Electronic Components Industry: Smartphones, keyless switches, various small sensors - Pharmaceuticals / Food / Cosmetics Industry: Bottle containers, syringes, vials, eye drop containers, pillow packaging, PTP packaging We will propose the most suitable leak testers for each industry. 【 ISO Certification 】JIS Q 9001:2015 (ISO 9001:2015)

This is a collection of links to Fukuda's technical columns. It covers various topics related to leak tests and more... Please check the related links for more information.